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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

GaAs VLSI for aerospace electronics

Advanced aerospace electronics systems require high-speed, low-power, radiation-hard, digital components for signal processing, control, and communication applications. GaAs VLSI devices provide a number of advantages over silicon devices including higher carrier velocities, ability to integrate with high performance optical devices, and high-resistivity substrates that provide very short gate delays, good isolation, and tolerance to many forms of radiation. However, III-V technologies also have disadvantages, such as lower yield compared to silicon MOS technology. Achieving very large scale integration (VLSI) is particularly important for fast complex systems. At very short gate delays (less than 100 ps), chip-to-chip interconnects severely degrade circuit clock rates. Complex systems, therefore, benefit greatly when as many gates as possible are placed on a single chip. To fully exploit the advantages of GaAs circuits, attention must be focused on achieving high integration levels by reducing power dissipation, reducing the number of devices per logic function, and providing circuit designs that are more tolerant to process and environmental variations. In addition, adequate noise margin must be maintained to ensure a practical yield.

Larue, G.↗
DOE OSTI2026

Development of Data-Driven Models for Performance Prediction and Chemical Dosing of a Full-Scale Controlled Phosphorus Precipitation Reactor

This study evaluated the use of data-driven models to improve control of a struvite precipitation reactor that removes phosphorus from wastewater while producing a fertilizer product. The researchers developed predictive models for influent orthophosphate concentration, effluent orthophosphate concentration, and phosphorus removal using operational data from a full-scale MagPrex™ reactor at a water resource recovery facility in Denver, Colorado. Model predictions were used to recommend magnesium chloride dosing adjustments needed to achieve a target effluent phosphorus concentration. Several machine learning approaches were tested, with ridge regression providing the best predictions for influent orthophosphate concentration and phosphorus removal, and XGBoost providing the best predictions for effluent orthophosphate concentration. Simulation results indicated that the decision-support approach could correctly identify dosing adjustments in most cases and reduce chemical use. Full-scale implementation achieved lower accuracy due to changing operating conditions and limited historical data in some operating ranges. Here, the results demonstrate the potential of data-driven tools to support phosphorus recovery process control while also identifying practical limitations that affect deployment in full-scale systems.

42 ENGINEERING↗
NASA NTRS2001

Numerical Study of the Role of Shallow Convection in Moisture Transport and Climate

The objective of this investigation was to study the role of shallow convection on the regional water cycle of the Mississippi and Little Washita Basins of the Southern Great Plains (SGP) using a 3-D mesoscale model, the PSU/NCAR MM5. The underlying premise of the project was that current modeling of regional-scale climate and moisture cycles over the continents is deficient without adequate treatment of shallow convection. At the beginning of the study, it was hypothesized that an improved treatment of the regional water cycle can be achieved by using a 3-D mesoscale numerical model having high-quality parameterizations for the key physical processes controlling the water cycle. These included a detailed land-surface parameterization (the Parameterization for Land-Atmosphere-Cloud Exchange (PLACE) sub-model of Wetzel and Boone), an advanced boundary-layer parameterization (the 1.5-order turbulent kinetic energy (TKE) predictive scheme of Shafran et al.), and a more complete shallow convection parameterization (the hybrid-closure scheme of Deng et al.) than are available in most current models. PLACE is a product of researchers working at NASA's Goddard Space Flight Center in Greenbelt, MD. The TKE and shallow-convection schemes are the result of model development at Penn State. The long-range goal is to develop an integrated suite of physical sub-models that can be used for regional and perhaps global climate studies of the water budget. Therefore, the work plan focused on integrating, improving, and testing these parameterizations in the MM5 and applying them to study water-cycle processes over the SGP. These schemes have been tested extensively through the course of this study and the latter two have been improved significantly as a consequence.

Seaman, Nelson L.↗
NASA NTRS2005

R and D work on the constrained vapor bubble system for a microgravity experiment

We are working with Project Scientists R. Balasubramanian and Sang Young Son, and a NASA Projects Team headed by Sue Motil at the Glenn Research Center on the design and development of an experimental system for use on the International Space Station during the year 2006. John Eustace is the coordinator for the flight experiment at Zin-Tech (previously Northrop-Grumman) for the design and development of the Constrained Vapor Bubble Heat Exchanger, CVBHX, cell which will fit into the Light Microscope Module, LMM. Good progress is being made. The CDR for the LMM being developed was held on December 10-1 1,2003. Experimental results obtained under microgravity conditions will be compared with those obtained at Rensselaer. Basic and applied research at Rensselaer continues on the experimental and theoretical details associated with passive phase change heat transfer processes controlled by interfacial forces in the CVBHX. The extensive results of our current research are presented in the 23 external publications listed below. Twenty-two external presentations have been given. Briefly, evaporation/condensation data from both vertical and horizontal CVBHX systems were obtained and analyzed for both polar (wetting) and apolar (partially wetting) fluids. The vertical system is axi-symmetric, but strongly effected by gravity. Whereas, the horizontal system is asymmetric, but weakly effected by gravity. Therefore, there will be significant differences in the operation of the cell in the earth s environment versus the operation under microgravity conditions. Due to its relative large size, the system s performance should be optimum under micro-gravity conditions, where the CVBHX should be a very effective passive heat exchanger. The CVBHX was found to be an ideal experimental setup in which to study the effects of interfacial phenomena on both the evaporation and drop-wise condensation processes. The optical technique (Image Analyzing Interferometry, IAI), which is based on the measurement and analysis of the reflectivity pattern of a thin film, was significantly improved. The accuracy of the IAI system is of critical importance to the success of the mission because it is used to measure the details of the pressure field in the liquid by measuring the film thickness profile. The accuracy was found to be excellent and various publications/presentations documenting these new results were written. Significant new results were also obtained for the effect of the oscillating contact line region on evaporation. Three doctoral students graduated under this grant. All three work in US industry, two for Intel. Another doctoral student is in his third year of study and will finish under an extension of the NASA grant: # NNC05GA27G.

Wayner, P. C., Jr.↗
NASA NTRS1994

Open solutions to distributed control in ground tracking stations

The advent of high speed local area networks has made it possible to interconnect small, powerful computers to function together as a single large computer. Today, distributed computer systems are the new paradigm for large scale computing systems. However, the communications provided by the local area network is only one part of the solution. The services and protocols used by the application programs to communicate across the network are as indispensable as the local area network. And the selection of services and protocols that do not match the system requirements will limit the capabilities, performance, and expansion of the system. Proprietary solutions are available but are usually limited to a select set of equipment. However, there are two solutions based on 'open' standards. The question that must be answered is 'which one is the best one for my job?' This paper examines a model for tracking stations and their requirements for interprocessor communications in the next century. The model and requirements are matched with the model and services provided by the five different software architectures and supporting protocol solutions. Several key services are examined in detail to determine which services and protocols most closely match the requirements for the tracking station environment. The study reveals that the protocols are tailored to the problem domains for which they were originally designed. Further, the study reveals that the process control model is the closest match to the tracking station model.

Heuser, William Randy↗
NASA NTRS2020

Calibration of the 11x11-Foot Transonic Wind Tunnel at NASA Ames Research Center

A static pipe calibration characterizing the streamwise static pressure distribution was conducted at the 11-By 11-Foot Transonic Wind Tunnel at NASA Ames Research Center. This data is used to determine the local Mach number within the test section and evaluate buoyancy corrections to axial force measurements. The 60 foot long, 6 inch diameter pipe contained 444 static pressure taps spanning the test section and nozzle regions of the tunnel. The forward end of the pipe extends into the settling chamber and is held by four cables mounting to the tunnel shell, and the aft end is fixed on the institutional model support system. A hydraulic cylinder at the aft end of the pipe provides tension on the system to reduce vibration and to keep the pipe as level as possible throughout the test section. The previous calibration was improved upon by using pressure scanners with greater accuracy, ensuring a uniform pressure tube length for each tap to control pneumatic lag, optically tracking any streamwise movement of the pipe, and more tightly controlling the tunnel condition set points. Typically this calibration is conducted with the pipe on tunnel centerline and 33 inches below centerline for sting-mounted models and semi-span (i.e. floor-mounted) models respectively, however schedule demands permitted only the centerline calibration. The semi-span calibration is planned to be completed in the summer of 2020. Immediately following the static pipe calibration, a shorter, 9 foot static pipe used as the calibration check standard was installed to obtain its first post-calibration pressure dataset. This short static pipe consists of 148 static pressure taps distributed along the pipe section and one total pressure tap at the end of an ogive nose. Performing the calibration test and its check standard back-to-back allows this dataset to establish a reliable baseline for future calibration check standard testing. Over time the use of a calibration check standard offers the ability to assess the stability of the calibration through statistical process control in an efficient and costeffective manner, thereby potentially increasing the time required between full tunnel calibrations.

White, Bethany↗
NASA NTRS2005

NASA Tech Briefs, May 2005

Topics covered include: Fastener Starter; Multifunctional Deployment Hinges Rigidified by Ultraviolet; Temperature-Controlled Clamping and Releasing Mechanism; Long-Range Emergency Preemption of Traffic Lights; High-Efficiency Microwave Power Amplifier; Improvements of ModalMax High-Fidelity Piezoelectric Audio Device; Alumina or Semiconductor Ribbon Waveguides at 30 to 1,000 GHz; HEMT Frequency Doubler with Output at 300 GHz; Single-Chip FPGA Azimuth Pre-Filter for SAR; Autonomous Navigation by a Mobile Robot; Software Would Largely Automate Design of Kalman Filter; Predicting Flows of Rarefied Gases; Centralized Planning for Multiple Exploratory Robots; Electronic Router; Piezo-Operated Shutter Mechanism Moves 1.5 cm; Two SMA-Actuated Miniature Mechanisms; Vortobots; Ultrasonic/Sonic Jackhammer; Removing Pathogens Using Nano-Ceramic-Fiber Filters; Satellite-Derived Management Zones; Digital Equivalent Data System for XRF Labeling of Objects; Identifying Objects via Encased X-Ray-Fluorescent Materials - the Bar Code Inside; Vacuum Attachment for XRF Scanner; Simultaneous Conoscopic Holography and Raman Spectroscopy; Adding GaAs Monolayers to InAs Quantum-Dot Lasers on (001) InP; Vibrating Optical Fibers to Make Laser Speckle Disappear; Adaptive Filtering Using Recurrent Neural Networks; and Applying Standard Interfaces to a Process-Control Language.

Source record↗
DOE OSTI2024

In situ x-ray imaging to understand subsurface behavior during continuous wave laser drilling

A limited understanding regarding the underlying dynamics and mechanisms of material removal during continuous wave laser drilling has presented significant challenges in achieving precision and process control. Here, to address this, we employed high-fidelity, in situ synchrotron x-ray imaging to reveal previously unknown material behaviors during continuous wave laser drilling with power modulation. Our findings highlight that high-aspect ratio drill holes are achieved when the laser modulation frequency falls within the range of 8–12 kHz, provided that the laser average power and modulation amplitude levels meet the specified limits. Under these conditions, we identified a material removal mechanism driven by incremental accumulation of recoil pressure that gradually pushes material upward from deep within the substrate to the surface. This mechanism manifested as a low-frequency fluctuation in the vapor depression depth, resulting in periodic instances of material ejection. Furthermore, our study underscores that rapid expansion of the melt pool and the widening of the drill hole opening can impede effective material removal by redirecting energy from material ejection to increasing the melt pool size. This investigation contributes essential insights into the subsurface dynamics involved in the drilling of high-aspect ratio holes, furthering our fundamental understanding of this intricate process.

47 OTHER INSTRUMENTATION↗
NASA NTRS2011

NASA Tech Briefs, December 2011

Topics covered include: 1) SNE Industrial Fieldbus Interface; 2) Composite Thermal Switch; 3) XMOS XC-2 Development Board for Mechanical Control and Data Collection; 4) Receiver Gain Modulation Circuit; 5) NEXUS Scalable and Distributed Next-Generation Avionics Bus for Space Missions; 6) Digital Interface Board to Control Phase and Amplitude of Four Channels; 7) CoNNeCT Baseband Processor Module; 8) Cryogenic 160-GHz MMIC Heterodyne Receiver Module; 9) Ka-Band, Multi-Gigabit-Per-Second Transceiver; 10) All-Solid-State 2.45-to-2.78-THz Source; 11) Onboard Interferometric SAR Processor for the Ka-Band Radar Interferometer (KaRIn); 12) Space Environments Testbed; 13) High-Performance 3D Articulated Robot Display; 14) Athena; 15) In Situ Surface Characterization; 16) Ndarts; 17) Cryo-Etched Black Silicon for Use as Optical Black; 18) Advanced CO2 Removal and Reduction System; 19) Correcting Thermal Deformations in an Active Composite Reflector; 20) Umbilical Deployment Device; 21) Space Mirror Alignment System; 22) Thermionic Power Cell To Harness Heat Energies for Geothermal Applications; 23) Graph Theory Roots of Spatial Operators for Kinematics and Dynamics; 24) Spacesuit Soft Upper Torso Sizing Systems; 25) Radiation Protection Using Single-Wall Carbon Nanotube Derivatives; 26) PMA-PhyloChip DNA Microarray to Elucidate Viable Microbial Community Structure; 27) Lidar Luminance Quantizer; 28) Distributed Capacitive Sensor for Sample Mass Measurement; 29) Base Flow Model Validation; 30) Minimum Landing Error Powered-Descent Guidance for Planetary Missions; 31) Framework for Integrating Science Data Processing Algorithms Into Process Control Systems; 32) Time Synchronization and Distribution Mechanisms for Space Networks; 33) Local Estimators for Spacecraft Formation Flying; 34) Software-Defined Radio for Space-to-Space Communications; 35) Reflective Occultation Mask for Evaluation of Occulter Designs for Planet Finding; and 36) Molecular Adsorber Coating

Source record↗
NASA NTRS1978

Thermal metamorphism of primitive meteorites. VII - Mineralogy-petrology of heated Murchison /C2/ and alteration of C30 and other chondrites

Alterations caused by week-long heating of Murchison in a low-pressure environment at 400-1400 C are of two types: thermodynamically favored kinetically controlled or thermodynamically controlled rapid processes. Kinetically controlled changes pertinent to chondritic evolution and which vary progressively with temperature in heated Murchison include: chondrule blurring; matrix coarsening; increasing mean Fa and Fs contents of ferromagnesian silicates; equilibration of olivine; increasing Mg/Si, Ca/Si, Al/Si, and Cr/Si and decreasing Fe/Si, Ni/Si, and S/Si in matrix; Cr loss from kamacite; and homogenization and Ni-zoning in taenite at high temperatures. Low-temperature thermodynamically controlled changes include: transformation of high-Ni troilite to low-Ni and formation of Ni- and Co-rich metal from pentlandite. High-temperature changes include formation of Cr-rich magnetite and formation of a Ni-rich sulfide similar to that found in highly altered chondrites. Trends resulting from processes of both kinds in Murchison are consistent with characteristics of a postulated C30 metamorphic suite, while those changes caused by reactions of the second kind are similar to those in heavily shock-heated ordinary chondrites and the heavily metamorphosed C5-6 chondrite, Mulga West. Either the simulations support the metamorphic origin of the C30 suite and other thermally induced changes or the natural alterations support the utility of laboratory simulations in studying meteoritic evolution.

Matza, S. D.↗
NASA NTRS2013

Fabrication Methods for Adaptive Deformable Mirrors

Previously, it was difficult to fabricate deformable mirrors made by piezoelectric actuators. This is because numerous actuators need to be precisely assembled to control the surface shape of the mirror. Two approaches have been developed. Both approaches begin by depositing a stack of piezoelectric films and electrodes over a silicon wafer substrate. In the first approach, the silicon wafer is removed initially by plasmabased reactive ion etching (RIE), and non-plasma dry etching with xenon difluoride (XeF2). In the second approach, the actuator film stack is immersed in a liquid such as deionized water. The adhesion between the actuator film stack and the substrate is relatively weak. Simply by seeping liquid between the film and the substrate, the actuator film stack is gently released from the substrate. The deformable mirror contains multiple piezoelectric membrane layers as well as multiple electrode layers (some are patterned and some are unpatterned). At the piezolectric layer, polyvinylidene fluoride (PVDF), or its co-polymer, poly(vinylidene fluoride trifluoroethylene P(VDF-TrFE) is used. The surface of the mirror is coated with a reflective coating. The actuator film stack is fabricated on silicon, or silicon on insulator (SOI) substrate, by repeatedly spin-coating the PVDF or P(VDFTrFE) solution and patterned metal (electrode) deposition. In the first approach, the actuator film stack is prepared on SOI substrate. Then, the thick silicon (typically 500-micron thick and called handle silicon) of the SOI wafer is etched by a deep reactive ion etching process tool (SF6-based plasma etching). This deep RIE stops at the middle SiO2 layer. The middle SiO2 layer is etched by either HF-based wet etching or dry plasma etch. The thin silicon layer (generally called a device layer) of SOI is removed by XeF2 dry etch. This XeF2 etch is very gentle and extremely selective, so the released mirror membrane is not damaged. It is possible to replace SOI with silicon substrate, but this will require tighter DRIE process control as well as generally longer and less efficient XeF2 etch. In the second approach, the actuator film stack is first constructed on a silicon wafer. It helps to use a polyimide intermediate layer such as Kapton because the adhesion between the polyimide and silicon is generally weak. A mirror mount ring is attached by using adhesive. Then, the assembly is partially submerged in liquid water. The water tends to seep between the actuator film stack and silicon substrate. As a result, the actuator membrane can be gently released from the silicon substrate. The actuator membrane is very flat because it is fixed to the mirror mount prior to the release. Deformable mirrors require extremely good surface optical quality. In the technology described here, the deformable mirror is fabricated on pristine substrates such as prime-grade silicon wafers. The deformable mirror is released by selectively removing the substrate. Therefore, the released deformable mirror surface replicates the optical quality of the underlying pristine substrate.

Toda, Risaku↗
DOE OSTI2026

Mechanical characterization of fine-grain dispersion-strengthened tungsten as a plasma facing material

Field-Assisted Sintering Technology (FAST) was used to produce fine-grained, dispersion-strengthened tungsten (W) materials. Investigated materials 4138, 4353, and 4355 composed of 3 wt% ZrC sintered at 1800 °C, 5 wt% ZrC sintered at 1800 °C, and 3 wt% ZrC sintered at 2000 °C, respectively. They were compared against ITER-grade W. A series of mechanical and thermal property testing and microstructure studies were conducted to study them as a potential plasma facing material (PFM) for fusion reactors. Hardness testing showed that manufacturing conditions substantially altered hardness. Material 4355 had an average HV10 value of 497.2 ± 16.8, slightly higher than ITER-grade at 378.5 ± 40.3. However, material 4353 was substantially higher with an HV10 value of 738.9 ± 31.7 over the investigated temperature range. Electron Backscatter Diffraction (EBSD) analysis showed that FAST produced substantially smaller grains than the hot-rolled ITER-grade W material, offering notable control over grain size. Materials 4353 and 4355 had grain sizes of 0.44 ± 0.20 µm and 3.67 ± 0.89 µm, respectively, whereas ITER-grade 27.14 ± 19.76 µm at room temperature. The fine grain structures showed no net coarsening after 1 hr. anneals up to 1800 °C, several hundred degrees above the 1100 – 1500 °C recrystallization range reported for conventional W. Inverse application of the Zener pinning relationship to the measured grain sizes indicates that these two FAST sintering conditions produce markedly different effective dispersoid populations, with effective particle diameters of approximately 90 nm at a peak sintering temperature of 1800 °C and approximately 460 nm at 2000 °C, respectively. This result demonstrates that the FAST thermal condition itself, and not the nominal ZrC content alone, governs the pinning effectiveness of the dispersion. Thermal diffusivity measurements support this finding independently. Materials of identical composition sintered at different temperatures differ by approximately 19% in measured thermal diffusivity with statistically indistinguishable density, while materials of different composition and sintering temperature converge to within approximately 2%. At a representative divertor heat flux of 10 MW/m², the lower thermal conductivity of the fine-grained materials corresponds to approximately 28 to 33 °C per millimeter of armor thickness relative to ITER-grade W, traded against a substantially larger margin to recrystallization-driven degradation. While high temperature tensile testing revealed likely contamination that motivates refinement of the manufacturing process, FAST-produced, fine-grained, dispersion-strengthened W offers process-controlled microstructural stability well above the operating temperatures of conventional W and supports its continued development as a PFM for economically viable commercial fusion power.

Parker, Gabe [ORNL] (ORCID:0000000190394100)↗
DOE OSTI2026

Using Best Basis Inventory Data to Direct Strategies for Real Time Monitoring of Hanford High Level Waste – 26226

The potential to accelerate the processing of low- and high-level tank waste by applying real-time monitoring (RTM) of chemical and physical properties has prompted research into the suitability of multiple analytical methods for that purpose. The broad variety of waste stream properties and the large number of analytes of interest (as evidenced by Waste Acceptance Criteria (WAC) and Process Control Limit (PCL) lists) lead to an overwhelming set of possible analytical scenarios. This report describes the use of Best Basis Inventory (BBI) data to find the most relevant analytical targets for the specific case of monitoring the blending of High Level Waste from multiple tanks prior to introduction into a vitrification facility. Campaigns for blending this waste to minimize the risk of exceeding WACs and PCLs have been proposed. However, the predicted compositions of the blended materials do not incorporate any uncertainties that may be associated with the representativeness of the waste layer samples or the laboratory analyses that generated the BBI data. Also, they do not include any uncertainty associated with the precision of collecting highly specific fractions of the layers during a blending campaign or any inhomogeneities that may exist in those layers. Monte Carlo methods are used to apply uncertainties to the compositions of the individual layers specified in the campaign recipes. The resulting variations in the compositions of the blended materials allow estimation of the risks of exceeding WACs and PCLs for each campaign. A critical subset of WACs/PCLs – NOx, NaK, AlFeZr, and S – are especially at risk of being exceeded in multiple campaigns. These analytes should be the focus of instrument development. We also have extracted the expected solid/supernate distribution for these analytes, which establishes important performance criteria for individual analytical methods. The BBI data also permits an understanding of the different chemical forms in which the analytes appear. Thus, the need to establish instrumental sensitivity to these forms can be gainfully addressed. Although concentrating on one specific application – the blending of tank waste - this approach should be generalizable for the analysis of other possible RTM applications for waste processing.

Lascola, Robert [Savannah River National Laborator↗
DOE OSTI2025

Radiation‐Resistant Aluminum Alloy for Space Missions in the Extreme Environment of the Solar System

Future human exploration of the solar system demands advanced materials capable of withstanding extreme environments, particularly exposure to solar energetic particle radiation. Current material selection criteria for space applications prioritize a high strength-to-weight ratio, high corrosion resistance and manufacturability, favoring age-hardenable Al-based alloys. However, conventional precipitation-hardened Al alloys suffer from irradiation-assisted dissolution of strengthening phases at doses as low as 0.2 displacements-per-atom (dpa), undermining their performance. Furthermore, these alloys develop radiation-induced defects, such as dislocation loops and voids, even at low doses. This study presents a novel ultrafine-grained (UFG) Al-based alloy, designed using the crossover alloying concept and strengthened by T-phase precipitates, featuring a chemically-complex structure with 162 atoms in its unit cell composed of Mg 32 (Zn,Al) 49 . It is showed that T-phase precipitates have exceptional radiation tolerance up to 24 dpa. Owing to the nanoscale UFG structure, dislocation loops are suppressed, and voids are only observed beyond 75 dpa. Microtensile tests up to 20 dpa confirm the preservation of mechanical performance under irradiation. The results underline the potential of this alloy as a radiation-resistant, lightweight material for future space applications. Three key strategies enable this performance: (i) stabilization of a UFG microstructure, (ii) T-phase precipitation featuring a highly negative Gibbs free energy and chemically-complex giant unit cell, and (iii) precise process control to prevent grain growth during heat treatment and irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Defining Golden Batches in Biomanufacturing Processes From Internal Metabolic Activity to Detect Process Changes That May Affect Product Quality

ABSTRACT Cellular metabolism plays a role in the observed variability of a drug substance's Critical Quality Attributes (CQAs) made by biomanufacturing processes. Therefore, here we describe a new approach for monitoring biomanufacturing processes that measures a set of metabolic reaction rates (named Critical Metabolic Parameters (CMP) in addition to the macroscopic process conditions currently being used as Critical Process Parameters (CPP) for biomanufacturing. Constraint‐based systems biology models like Flux Balance Analysis (FBA) are used to estimate metabolic reaction rates, and metabolic rates are used as inputs for multivariate Batch Evolution Models (BEM). Metabolic activity was reproducible among batches and could be monitored to detect a deliberately induced macroscopic process shift (i.e., temperature change). The CMP approach has the potential to enable “golden batches” in biomanufacturing processes to be defined from the internal metabolic activity and to aid in detecting process changes that may impact the quality of the product. Overall, the data suggested that monitoring of metabolic activity has promise for biomanufacturing process control.

Biotechnology & Applied Microbiology↗
DOE OSTI2024

Riverine dissolved organic matter transformations increase with watershed area, water residence time, and Damköhler numbers in nested watersheds

Abstract Quantifying the relative influence of factors and processes controlling riverine ecosystem function is essential to predicting future conditions under global change. Dissolved organic matter (DOM) is a fundamental component of riverine ecosystems that fuels microbial food webs, influences nutrient and light availability, and represents a significant carbon flux globally. The heterogeneous nature of DOM molecular composition and its propensity for interaction (i.e., functional diversity) can characterize riverine ecosystem function across spatiotemporal scales. To investigate fundamental drivers of DOM diversity, we collected seasonal water samples from 42 nested locations within five watersheds spanning multiple watershed sizes (~ 5 to 30,000 km 2 ) across the United States. Patterns in DOM molecular richness, aromaticity, relative abundance of N-containing formulas, and putative biochemical transformations derived from high-resolution mass spectrometry were assessed across gradients of explanatory variables associated with watershed characteristics (e.g., watershed area, water residence time, land cover). We found that putative biochemical transformations were more strongly related to explanatory variables across watersheds than common bulk DOM parameters and that watershed area, surface water residence time and derived Damköhler numbers representing DOM reactivity timescales were strong predictors of DOM diversity. The data also indicate that catchment-specific land cover factors can significantly influence DOM diversity in diverging directions. Overall, the results highlight the importance of considering water residence time and land cover when interpreting longitudinal patterns in DOM chemistry and the continued challenge of identifying generalizable drivers that are transferable across watershed and regional scales for application in Earth system models. This work also introduces a Findable Accessible Interoperable Reusable (FAIR) dataset (> 300 samples) to the community for future syntheses.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

In-situ sensor monitoring of multi-class gas porosity formation in laser powder bed fusion using convolutional neural network

In-situ monitoring of defect formation remains a significant challenge in the laser powder bed fusion (LPBF) process. Recent advances have enabled real-time defect detection with machine learning and in-situ sensing technologies; however, most studies focus on binary classification of keyhole pores, limiting nuanced multi-class pore differentiation and formation mechanisms. This work introduces a multi-class pore detection framework (no pore, small pores < 15 µm, and large pores > 15 µm) by leveraging photodiode sensor data alongside high-fidelity synchrotron X-ray imaging. The 15 µm threshold is selected to distinguish between two fundamentally different defect mechanisms, following the physical size-mechanism boundary established by prior high-resolution synchrotron X-ray characterization of Al6061 LPBF. Distinguishing these classes is critical because large keyhole pores are structurally detrimental, whereas small gas pores are often benign, requiring different process control strategies. Thermal emission monitoring data collected simultaneously with high-speed X-ray imaging at the Stanford Synchrotron Radiation Lightsource (SSRL), are correlated with subsurface melt pool dynamics to establish ground truth. Continuous Wavelet Transform (CWT) with optimized parameters converts the photodiode time-series signals into time–frequency images, facilitating feature extraction. Convolutional Neural Networks (CNN) are then applied for real-time multi-class pore classification in an average inference time of 1 ms per signal window. It achieves 79% accuracy and an Area Under the Receiver Operating Characteristic curve (AUC ROC) score of 0.89 with five-fold cross-validation. The results demonstrate that coupling CWT-based feature engineering with CNN architecture enables reliable multi-class pore detection in Al6061 builds using affordable in-situ sensors. This approach advances scalable and affordable quality assurance in additive manufacturing by moving beyond binary defect detection toward more nuanced classification of porosity mechanisms with in-situ sensors and machine learning.

Laser powder bed fusion, Multi-class pores, In-sit↗
DOE OSTI2025

Dissolution of Nb(C,N) and (Ti,V)N in the Coarse-Grained Heat-Affected Zone of Electric Resistance Welded X65 Line Pipe

Nb-rich and Ti/V-rich precipitates were introduced into the X65 linepipe via thermomechanical controlled processing. Their dissolution kinetics were investigated in the coarse-grained heat-affected zone after electric resistance welding. Nb-rich precipitates were found to dissolve completely, whereas Ti/V-rich precipitates were found to dissolve partially, because of slower dissolution kinetics. In conclusion, a complete dissolution of Nb-rich precipitates was associated with significant austenite grain coarsening, which promoted bainite as a quench product, which might have reduced the impact toughness.

microstructure↗